Separator with fluid distribution features for use with a membrane electrode assembly in a fuel cell

ABSTRACT

Electrochemically inactive separators may be employed at the periphery of membrane electrode assemblies in fuel cells (such as solid polymer electrolyte fuel cells) to separate the various fluids within (for example, reactants, coolant). Complex fluid distribution features may be incorporated into these separators, thereby desirably simplifying the design and manufacture of other fuel cell components, such as the flow field plates employed to distribute fluids to the cell electrodes. This is particularly advantageous in fuel cells comprising thin, corrugated flow field plates. The separators may be bonded to the membrane electrode assemblies to form convenient, unitary structures.

FIELD OF THE INVENTION

[0001] The present invention relates to fluid separators for isolatingthe fluids on each side of a membrane electrode assembly in a fuel cell.More particularly, it relates to separators that attach to the membraneelectrode assembly and comprise complex distribution features for thefluids.

BACKGROUND OF THE INVENTION

[0002] Fuel cell systems are currently being developed for use as powersupplies in numerous applications, such as automobiles and stationarypower plants. Such systems offer promise of economically deliveringpower with environmental and other benefits.

[0003] Fuel cells convert reactants, namely fuel and oxidant, togenerate electric power and reaction products. Fuel cells generallyemploy an electrolyte disposed between two electrodes, namely a cathodeand an anode. A catalyst typically induces the desired electrochemicalreactions at the electrodes. Preferred fuel cell types include solidpolymer electrolyte fuel cells that comprise a solid polymer electrolyteand operate at relatively low temperatures.

[0004] During normal operation of a solid polymer electrolyte fuel cell,fuel is electrochemically oxidized at the anode catalyst, typicallyresulting in the generation of protons, electrons, and possibly otherspecies depending on the fuel employed. The protons are conducted fromthe reaction sites at which they are generated, through the electrolyte,to electrochemically react with the oxidant at the cathode catalyst. Thecatalysts are preferably located at the interfaces between eachelectrode and the adjacent electrolyte.

[0005] A broad range of fluid reactants can be employed in solid polymerelectrolyte fuel cells and may be supplied in either gaseous or liquidform. For example, the oxidant stream may be substantially pure oxygengas or a dilute oxygen stream such as air. The fuel may be substantiallypure hydrogen gas, a gaseous hydrogen-containing reformate stream, or anaqueous liquid methanol mixture in a direct methanol fuel cell.Reactants are directed to the fuel cell electrodes and are distributedto catalyst therein by means of fluid diffusion layers.

[0006] Solid polymer electrolyte fuel cells employ a membrane electrodeassembly (“MEA”), which comprises the solid polymer electrolyte orion-exchange membrane disposed between the two electrodes. Eachelectrode contains a catalyst layer, comprising an appropriate catalyst,located next to the solid polymer electrolyte. The catalyst may be, forexample, a metal black, an alloy or a supported metal catalyst, forexample, platinum on carbon. The catalyst layer typically containsionomer, which may be similar to that employed for the solid polymerelectrolyte (for example, Nafion®). The catalyst layer may also containa binder, such as polytetrafluoroethylene. The electrodes may alsocontain a substrate (typically a porous electrically conductive sheetmaterial) that may be employed for purposes of mechanical support and/orreactant distribution, thus serving as a fluid diffusion layer.

[0007] The MEA is typically disposed between two plates to form a fuelcell assembly. The plates act as current collectors and provide supportfor the adjacent electrodes. The assembly is typically compressed (forexample, of order of 70 pounds per square inch (psi) overall) to ensuregood electrical contact between the plates and the electrodes, inaddition to good sealing between fuel cell components. A plurality offuel cell assemblies may be combined in series or in parallel to form afuel cell stack. In a fuel cell stack, a plate is usually shared betweentwo adjacent MEAs, and thus also serves as a separator to fluidlyisolate the fluid streams of the two adjacent MEAs.

[0008] Further, flow fields are typically incorporated into bothsurfaces of such plates in order to direct reactants across theelectrochemically active surfaces of the fluid diffusion electrodes orelectrode substrates. The flow fields typically comprise fluiddistribution channels separated by landings. The channels providepassages for the distribution of reactant to the electrode surfaces andalso for the removal of reaction products and depleted reactant streams.The landings act as mechanical supports for the fluid diffusion layersin the MEA and provide electrical contact thereto. Ports and other fluiddistribution features are typically formed in the surfaces at theperiphery of the flow field plates. When assembled into a fuel cellstack, the stacked ports can form internal manifolds for distribution ofthe fluids throughout the stack. The other distribution featurestypically are provided to distribute fluids from the ports to theappropriate flow fields. PCT/International Publication No. WO 00/41260,for instance, illustrates flow field plates with flow fields comprisinga plurality of straight, parallel channels. The flow fields are fluidlyconnected to manifold openings in header regions at the periphery of theplates by a series of complex passages formed in the plate surfaces.

[0009] Sealing of some sort is generally required around the edges ofthe MEAs to isolate the different fluids on each side of the MEA. Inprinciple, the membrane electrolyte in the MEA may be oversized andextend significantly beyond the electrochemically active area in orderto be employed as a sealing gasket. However, membrane electrolytematerial is generally expensive and has relatively poor mechanicalproperties for this purpose. Thus, it is preferred to employ other meansfor effecting edge seals.

[0010] As an alternative, U.S. Pat. No. 5,464,700 discloses a gasketedmembrane electrode assembly that employs gasketing material at themembrane periphery, rather than the membrane itself, as a gasket. Thegasketing material may be formed from an elastomeric material suitablefor cold bonding or bonding by heat and pressure. A non-hydrophilicthermoplastic elastomer is the preferred gasketing material (forexample, Santoprene brand gasketing material).

[0011] Further, U.S. Pat. No. 5,187,025 discloses a unitized cellassembly in which the edge of the MEA is extended with a laminatedplastic structure to give it strength and rigidity for sealing andsupport. Therein, the electrolyte membrane is surrounded with a plasticspacer having a thickness closely matched to that of the membrane. Athin, plastic film is bonded with an adhesive layer to both sides of themembrane and spacer so that the film and adhesive bridge the gaptherebetween. Porous electrodes with plastic frames are bonded to thecomposite membrane. The use of this type of structure permits theconstruction of a rigid cell frame, which can be made the same thicknessas the membrane electrode package.

[0012] In an effort to further improve fuel cell performance and toreduce the thickness and cost of fuel cell assemblies, there is a trendto use thinner components and especially thinner flow field plates. Aparticularly thin design for flow field plates employs corrugated flowfields which are characterized by features on one side that arecomplementary with features on the other side. Corrugated structures arereadily formed out of thin metallic sheets by stamping or rollingmethods. However, it is not so easy to use such methods to form featureson opposing sides of such sheets if the intended features are notsubstantially complementary. (Instead, engraving techniques may beemployed on thicker starting sheet material.) Yet, some desirablecorrugated flow field designs involve complex flow distribution andmechanical support features at the fluid inlet and outlet ports on oneor both sides of the plate which, in some cases, cross over similarlycomplex features on the opposite side of the plate. Further, somedesigns may involve features that interconnect channels within the flowfield itself (for example, which interconnect parallel flow channels attheir ends so as to form serpentine channels). It might not be possibleto form such features on both sides of a plate in a complementaryfashion, thereby complicating the fabrication of plates with corrugatedflow fields. For this and other reasons, it would be advantageous to beable to design and fabricate the components that distribute fluids toand from the flow fields more independently of the components thatcomprise the flow fields themselves.

SUMMARY OF THE INVENTION

[0013] Fluid distribution features for fluidly connecting manifolds tothe flow fields in a fuel cell may be incorporated in an “edge”separator attached to a membrane electrode assembly (MEA) instead ofbeing incorporated in a flow field plate. In this way, the fuel cell mayemploy flow field plates whose desired design and construction are notso compatible with the design and construction of the edge separator.

[0014] The separator is thus employed to separate and distribute fluidsat the periphery of a substantially planar MEA in the fuel cell. The MEAtypically comprises first and second porous electrodes (for example,anode and cathode) assembled onto opposing major surfaces of asubstantially planar membrane electrolyte. The fuel cell also comprisesfirst and second flow field plates adjacent major surfaces of the firstand second electrodes, respectively. However, the separator alsocomprises sealing surfaces for sealing engagement with the periphery ofthe MEA and with the first and second flow field plates in order toprevent fluids from each side of the MEA from mixing or from escapingfrom the fuel cell. Further, the separator comprises a first port forproviding passage of a first fluid (for example, a reactant such as thefuel) through the separator, and a first set of fluid distributionfeatures for fluidly connecting the first port to the flow field in thefirst flow field plate yet also for fluidly isolating the first portfrom the flow field in the second flow field plate.

[0015] The separator may also comprise additional ports, for instance, asecond port for providing passage of a second fluid (for example,another reactant, such as the oxidant, or a coolant) through theseparator, and a second set of fluid distribution features for fluidlyconnecting the second port to the flow field in the second flow fieldplate and for fluidly isolating the second port from the flow field inthe first flow field plate.

[0016] The first set of fluid distribution features may comprise aplurality of channels separated by lands for directing the first fluidto a plurality of channels in the first flow field plate. The second setof fluid distribution features may similarly comprise a plurality ofchannels separated by lands but for directing the second fluid to aplurality of channels in the second flow field plate. The separator canbe substantially planar with these first and second sets of fluiddistribution features on opposing major surfaces of the separator.

[0017] The separator may be made of a suitable thermoplastic sheet suchas a polyimide in which the fluid distribution features may be formed(by molding, engraving and similar forming techniques). Alternatively,the fluid distribution features may be applied to the thermoplasticsheet, for instance, by injection molding a suitable material (forexample, silicone elastomer) onto the material.

[0018] An assembly in which the separator is attached to the MEA can beprepared by bonding the separator to the periphery of the MEA. Theseparator may be bonded either directly to the MEA (for example, bybonding to the membrane electrolyte) or indirectly to the MEA (forexample, by bonding to first and second thermoplastic sheets whichpenetrate into and are bonded to the first and second porous electrodesrespectively at the periphery of the MEA; such thermoplastic sheets mayalso be employed to completely encapsulate the separator if desired). Inan alternative embodiment, the separator may even be formed from anextension of a fluid diffusion layer in a porous electrode in the MEA.Typically such fluid diffusion layers are similar in size to the activearea of the electrode. However, here, the fluid diffusion layer may beextended beyond the active area and may have appropriate port/s andfluid distribution features formed in the extension.

[0019] To distribute the fuel cell reactants both to and from theirassociated flow fields, the separator/MEA assembly may include anadditional fluid separator with the two separators sealingly engaged toopposite ends of the MEA. For convenience in assembling a complete fuelcell or fuel cell stack, the separators may also be bonded to adjacentflow field plates.

[0020] The aforementioned separators are particularly useful in certainsolid polymer electrolyte fuel cell stacks, for instance those employinghigh aspect ratio, rectangular MEAs and/or corrugated metallic flowfield plates.

BRIEF DESCRIPTION OF THE DRAWINGS

[0021]FIG. 1a is a schematic cross-sectional view of a prior art fuelcell assembly in a solid polymer electrolyte fuel cell stack and shows aMEA and associated flow field plates.

[0022]FIG. 1b shows a plan view of a prior art flow field plate for asolid polymer electrolyte fuel cell stack.

[0023]FIG. 2a shows a schematic cross-sectional view of a fuel cellassembly comprising edge separators.

[0024]FIG. 2b shows a plan view of a simple corrugated flow field platethat can be employed in the assembly depicted in FIG. 2a.

[0025]FIG. 2c is a schematic cross-sectional view along section A of thecorrugated flow field plate of FIG. 2b.

[0026]FIG. 3 shows an exploded view of an integrated separator-MEAassembly comprising a two-piece separator laminated to plastic sheets,which in turn are bonded to a MEA.

[0027]FIG. 4 shows an exploded view of an integrated separator-MEAassembly comprising a single-piece separator that is encapsulated byplastic sheets that are also bonded to a MEA.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENT(S)

[0028] A schematic cross-sectional view of a prior art fuel cellassembly in a solid polymer electrolyte fuel cell stack is shown in FIG.1a. For simplicity, only one MEA is shown along with its adjacent flowfield plates. A typical stack would comprise many such MEAs separated byshared bipolar flow field plates in which the fuel and oxidant flowfields would appear on opposite surfaces of each shared plate.

[0029] In FIG. 1, the MEA consists of solid polymer electrolyte membrane2 sandwiched between cathode 3 and anode 4. Flow field plates 5 and 6are positioned adjacent cathode 3 and anode 4 and provide oxidant andfuel thereto respectively. Gasket 1 provides a seal that prevents mixingof the fuel and oxidant on either side of the MEA and that preventsleaks to the external environment. Manifolds 7 and 8 for directing fueland oxidants to and from flow field plates 5 and 6 are formed by thealignment of openings provided in gasket 1 and plates 5 and 6. (Fluiddistribution features connecting the manifolds to the respective flowfields in plates 5 and 6 are not shown in this schematic.) To effectsealing, gasket 1 may be bonded to the MEA and also compressed betweenplates 5 and 6 in the vicinity of manifolds 7 and 8.

[0030]FIG. 1b shows a plan view of a representative elongated prior artflow field plate 10 for such a fuel cell stack. The surface shown inFIG. 1b may face and contact the anode side of an MEA and has a centralflow field 11 comprising a plurality of parallel substantially straightfuel channels 12 for distributing fuel over the anode surface.

[0031] Fuel channels 12 extend substantially between two opposing edgesof elongated fuel flow field plate 1. Fuel is admitted at fuel inletport 16, travels through fuel distribution passages 18, fuel channels12, fuel distribution passages 19, and exhausts at fuel outlet port 20.

[0032] Flow field plate 10 also has oxidant inlet port 21 and oxidantoutlet port 22, which are provided to distribute oxidant to and from acorresponding oxidant flow field located on the opposite surface ofplate 10. The other surface (not shown) of plate 10 may also comprise acentral oxidant flow field similar and complementary to that of fuelflow field 11, namely, a complementary set of parallel substantiallystraight oxidant channels. However, appropriate oxidant distributionfeatures for connecting oxidant ports 21 and 22 to such an oxidant flowfield would not however be complementary to fuel distribution passages18 and 19. Flow field plate 10 also has coolant inlet port 23 andcoolant outlet port 24 for distributing coolant to and from a coolantflow field located within plate 10. Such a coolant flow field may befabricated by making plate 10 in two pieces with appropriate fluiddistribution structures on each surface and then by bonding the twopieces together. Finally, FIG. 1b shows perimeter seal 25 whichcircumscribes the fuel channel area and the various ports to effectappropriate fluid seals.

[0033]FIG. 2a, on the other hand, shows a schematic cross-sectional viewof a fuel cell assembly comprising edge separators in which complexfluid diffusion features, similar in function to passages 18 and 19 inFIG. 1b, reside in the separators. Further, FIG. 2a illustrates a fuelcell construction comprising thin, corrugated, bipolar flow fieldplates. In FIG. 2a, the MEA components: electrolyte membrane 32, cathode33, and anode 34 may be similar to those in FIG. 1a. However, flow fieldplates 35 and 36 are formed from thin sheets and, as shown, are muchthinner at the periphery (35 a, 36 a) than plates 5 and 6 in FIG. 1a.The present separators can also be employed at each end of the MEA. Eachseparator 37 and 38 is made of two pieces 37 a, 37 b and 38 a, 38 brespectively that are bonded to the MEA and to each other in order toeffect appropriate fluid seals. Separators 37 and 38 may also be bondedto flow field plates 35 and 36. Fluid diffusion features (not shown inFIG. 1a) connecting manifolds 39 and 40 to the appropriate flow fieldsin plates 35 and 36 are provided on those surfaces of separators 37 and38 that are adjacent plates 35 and 36.

[0034] Separators 37 and 38 are desirably made of a moldablethermoplastic with mechanical and chemical resistance characteristicsthat are suitable for use in the fuel cell. For instance, the separatorsmay be made of a phenolic or preferably a polyimide plastic such asImidex™ of Westlake Plastics Company. Various sealing techniques may beemployed to seal and preferably bond such separators to the MEA.

[0035]FIG. 2b shows a plan view of a simple corrugated flow field plate35, which can be employed in the assembly depicted in FIG. 2a. Since thecomplex fluid distribution features connecting appropriate internalmanifolds to flow field 43 are not in flow field plate 35, the plate maybe readily formed from a thin metallic sheet by a stamping process orthe like. FIG. 2c shows a schematic cross-sectional view along section Aof corrugated flow field plate 35 of FIG. 2b. As depicted, plate 35comprises four ports (39 and 41 in separator 37 and 40 and 42 inseparator 38), which can be employed as fuel and oxidant inlets andoutlets. (The embodiment shown in FIGS. 2a, 2 b and 2 c is not providedwith a coolant flow field in plate 35.)

[0036]FIG. 3 shows an exploded view of an integrated separator-MEAassembly comprising a two-piece separator. As depicted, the integratedseparator-MEA assembly comprises three ports and is suitable for use ina fuel cell stack employing a coolant flow field. Exploded separator 50comprises upper and lower thermoplastic pieces 51 and 52 respectivelywhich are bonded together (for example, by thermal bonding). In FIG. 3,the MEA comprises cathode 55, anode 56, and electrolyte membrane 57.Complex fluid distribution features 60 are provided in the surface ofpiece 51 for connecting oxidant port 61 to the oxidant flow field in anadjacent flow field plate (not shown). Features 60 comprise a pluralityof channels 62 separated by lands 63.

[0037] Plastic bridging sheet 53 overlaps and is bonded to a portion ofupper separator piece 51. Sheet 53 also overlaps and is bonded to aportion of cathode 55, thereby effecting a seal between piece 51 andcathode 55. If bonded thermally, sheet 53 may be caused to penetrate thepores of cathode 55. In a like manner, plastic bridging sheet 54overlaps and is bonded to lower separator piece 52 and to anode 56.Sheets 53 and 54 are preferably made of a thin thermoplastic film withdesirable mechanical, chemical resistance, and bonding characteristics(for example, Kynar®). Additional spacing and sealing surfaces 64 areprovided at various locations around the periphery of piece 51 and theports therein for purposes of spacing from and sealing to an adjacentflow field plate (not shown). A seal between separator 50 and theadjacent flow field plate may be achieved by way of adhesive orcompression type seals. For instance, under adequate compressive force,surfaces 64 made of semi-rigid polyimide plastic could be made to pressinto the surface of an adjacent plate made of softer, deformableexpanded graphite in order to effect a compression seal.

[0038] As depicted, the embodiment of FIG. 3 is suited for use in a fuelcell stack employing coolant flow fields and thus may not employ thin,corrugated bipolar flow field plates. Still, having certain fluiddistribution features in the separator instead of the flow field platesmay be advantageous in this embodiment as well. For instance, expandedgraphite is commonly considered for use in making flow field plates.While it is relatively easy to mass produce expanded graphite plateswith simple flow field designs (for example, a plurality of straightparallel channels can be roller embossed therein), it can be difficultto also include more complex features (like features 60 in FIG. 3) inthe header regions of the expanded graphite plates. Thus, the presentseparators also offer advantages in fuel cell stacks that do not includecorrugated bipolar plates.

[0039] Other alternatives to the arrangement shown in FIG. 3 may also becontemplated. For instance, for compression sealing purposes, sealingsurfaces 64 and even fluid distribution features 60 may be formed byapplication of an elastomeric material, such as silicone, onto asemi-rigid polyimide (or other suitable material) base. Further, theelastomeric material may be applied so as to form a surface bridgebetween the separator and the MEA thereby accomplishing the attachmentand sealing functions provided by sheets 53 and 54 in FIG. 3.Elastomeric material may be applied in this manner using a liquidinjection molding process. Alternatively, the separator may be buttglued to the MEA instead of using bridging sheet 53 or may be made tooverlap an electrode and be bonded thereto.

[0040] Still further, FIG. 4 shows an exploded view of an alternativeintegrated separator-MEA assembly comprising a single-piece separator70. Here, separator piece 71 is completely encapsulated by plasticsheets 72 and 73. Sheets 72 and 73 also overlap and are bonded to MEA74. Sheets 72 and 73 are preferably made of a suitable thermoplastic(for example, Kynar™). The encapsulating and bonding can be achieved bystarting with a thinner separator piece 71 than that desired for thefinal separator thickness and then by overmolding it with sheets 72 and73 between heated dies in a molding press. The thickness of sheets 72,73 is selected such that the starting thickness of sheets 72, 73 pluspiece 71 is greater than that desired for the final separator thickness.During hot pressing, the overall thickness is reduced to that finallydesired. Manifold openings are opened in sheets 72 and 73 to conform tothose in the encapsulated piece 71. Also, sheets 72 and 73 are conformedto fluid distribution features 75 and to the sealing surfaces provided(not shown in FIG. 4). Thus, piece 71 may simultaneously be bonded toMEA 74 and completely encapsulated with a protective layer of plastic inone simple operation.

[0041] An advantage of this approach is that the thickness of theseparator can be custom matched to that of the attached MEA by using afloating platen in the molding press. Thus, the thickness tolerance ofmanufactured MEAs may be relaxed without negatively affecting alignmentof components in the stack. Another advantage is that encapsulating theseparator may be sufficient to protect it from the fuel cell environmentallowing other less corrosion resistant and less expensive materialchoices to be contemplated.

[0042] While particular elements, embodiments and applications of thepresent invention have been shown and described, it will be understood,of course, that the invention is not limited thereto since modificationsmay be made by those skilled in the art without departing from the scopeof the present disclosure, particularly in light of the foregoingteachings.

What is claimed is:
 1. A separator for separating and distributingfluids at the periphery of a substantially planar membrane electrodeassembly in a fuel cell, the membrane electrode assembly comprisingfirst and second porous electrodes assembled onto opposing majorsurfaces of a substantially planar membrane electrolyte, the fuel cellcomprising first and second flow field plates adjacent major surfaces ofthe first and second electrodes, respectively, the separator comprising:(a) sealing surfaces for sealing engagement with the periphery of themembrane electrode assembly and with the first and second flow fieldplates; (b) a first port for providing passage of a first fluid throughthe separator; and (c) a first set of fluid distribution features forfluidly connecting the first port to the flow field in the first flowfield plate and for fluidly isolating the first port from the flow fieldin the second flow field plate.
 2. The separator of claim 1 furthercomprising: (d) a second port for providing passage of a second fluidthrough the separator; and (e) a second set of fluid distributionfeatures for fluidly connecting the second port to the flow field in thesecond flow field plate and for fluidly isolating the second port fromthe flow field in the first flow field plate.
 3. The separator of claim1 wherein the first set of fluid distribution features comprises aplurality of channels separated by lands for directing the first fluidto a plurality of channels in the first flow field plate.
 4. Theseparator of claim 2 wherein the second set of fluid distributionfeatures comprises a plurality of channels separated by lands fordirecting the second fluid to a plurality of channels in the second flowfield plate.
 5. The separator of claim 2 wherein the separator issubstantially planar and the first and second sets of fluid distributionfeatures are on opposing major surfaces of the separator.
 6. Theseparator of claim 1 wherein the first fluid is a reactant.
 7. Theseparator of claim 2 wherein the first and second fluids are fuel andoxidant respectively and the first and second electrodes are an anodeand a cathode, respectively.
 8. The separator of claim 1 comprising athermoplastic sheet.
 9. The separator of claim 8 wherein thethermoplastic is a polyimide.
 10. The separator of claim 8 wherein thefirst set of fluid distribution features is formed in the thermoplasticsheet.
 11. The separator of claim 8 wherein the first set of fluiddistribution features is applied to the thermoplastic sheet.
 12. Theseparator of claim 11 wherein the first set of fluid distributionfeatures comprises silicone.
 13. A fuel cell comprising the separator ofclaim
 1. 14. The fuel cell of claim 13 wherein the separator is bondedto the periphery of the membrane electrode assembly.
 15. The fuel cellof claim 14 wherein the separator is bonded to the membrane electrolytein the membrane electrode assembly.
 16. The fuel cell of claim 14wherein the separator is bonded to first and second thermoplastic sheetsand the thermoplastic sheets penetrate into and are bonded to the firstand second porous electrodes respectively at the periphery of themembrane electrode assembly.
 17. The fuel cell of claim 16 wherein theseparator is encapsulated by the first and second thermoplastic sheets.18. The fuel cell of claim 14 wherein the separator is an extension of afluid diffusion layer in one of the electrodes.
 19. The fuel cell ofclaim 13 wherein the separator is bonded to the first flow field plate.20. The fuel cell of claim 13 wherein the membrane electrode assembly isrectangular.
 21. The fuel cell of claim 20 comprising an additionalseparator wherein the separator and the additional separator aresealingly engaged to opposite ends of the membrane electrode assembly.22. The fuel cell of claim 13 wherein the fuel cell is a solid polymerelectrolyte fuel cell.
 23. The fuel cell of claim 13 wherein the flowfield plate is corrugated.
 24. The fuel cell of claim 23 wherein theflow field plate is metallic.
 25. A method of separating anddistributing fluids in a fuel cell, the fuel cell comprising asubstantially planar membrane electrode assembly having first and secondelectrodes assembled onto opposing major surfaces of a substantiallyplanar membrane electrolyte, and first and second flow field platesadjacent major surfaces of the first and second electrodes respectively,the method comprising: (a) forming a first port in a separator to allowa first fluid to pass therethrough; (b) providing a first set of fluiddistribution features in the separator to fluidly connect the first portto the flow field in the first flow field plate and to fluidly isolatethe first port from the flow field in the second flow field plate; and(c) sealing the separator to the periphery of the membrane electrodeassembly and to the first and second flow field plates.
 26. The methodof claim 25 further comprising: (d) forming a second port in theseparator to allow a second fluid to pass therethrough; (e) providing asecond set of fluid distribution features in the separator to fluidlyconnect the second port to the flow field in the second flow field plateand to fluidly isolate the second port from the flow field in the firstflow field plate.
 27. The method of claim 25 wherein the first set offluid distribution features comprises a plurality of channels separatedby lands for directing the first fluid to a plurality of channels in thefirst flow field plate.